Wearables: Bridging the Human Element in World Class Manufacturing 4.0

Gamification of Human Metrics through Wearables

In the era of the fourth industrial revoution, World Class Manufacturing (WCM) is undergoing a remarkable transformation. The integration of wearable technology has not only revolutionized the manufacturing landscape but has also brought the analog nature of humans into the digital age. Wearables, with their smart technology, are breathing life into the principles of Content, Communication, Initiation, Intelligence, Influence, Enhancement, Interaction, and Network, and they are creating a seismic shift in the way we approach manufacturing.

The Essence of WCM 4.0

At the heart of WCM 4.0 lies a complex structure with three foundational elements: the Six S's (Safety, Sort, Shine, Set-in-place, Standardize, and Sustain), Group Activities, and Visual Management. These elements support the nine operational pillars: Focused Improvement, Autonomous Maintenance, Planned Maintenance, People Development, Equipment and Product Management, Quality Maintenance, Energy and Water Management, Office and Administration, and Safety, Health, and Environment. This structure isn't complete without its gable, meticulously tracking WCM metrics made up of Overall Leadership Excellence (OLE), Overall Process Efficiency (OPE) and Overall Equipment Effectiveness (OEE).

The Strength of a Chain: Individual Empowerment

The strength of any manufacturing setup hinges on the capabilities and efforts of its individuals. Wearables play a pivotal role in bringing the principles of WCM to life by seamlessly integrating the fourth industrial revolution technology into the manufacturing environment. The result? The elimination of paperwork, simplified data collection and manipulation, and instant access to vital information. The gable of the WCM structure focuses on people, processes and equipment, which are directly impacted and improved by wearables.

Challenges and Solutions

The road to embracing wearables in manufacturing isn't without its hurdles. Challenges include hardware architecture, communication protocols, wearable positioning, and the need for validated wearable technology through independent research. However, the integration of wearables through private 5G networks or the Industrial Wireless Network (IWN) presents a solution that offers flexibility, reliability, robustness, low latency, easy deployment, and industrial security.

The Anatomy of the IWN

The Industrial Wireless Network (IWN) comprises four vital components: Smart Entities, Nodes, Network Components, Displayers, and Servers. The world of smart entities in WCM wearables encompasses a wide range of devices, from rings and watches to exoskeletons and safety boots. These smart wearables enable real-time information exchange within the WCM model.

The Four Functions of WCM 4.0 Wearables

WCM 4.0 wearables serve four crucial functions: monitoring, supporting, training, and tracking. They monitor and control vital worker and task parameters, assess environmental workplace conditions, and support workers through exoskeletons and hands-free communication systems. Wearables simplify information management, enable data collection and storage, and enhance manufacturing design through augmented reality. Moreover, they provide training and track task correctness, ensuring continuous improvement.

Classifying Wearables

Wearables come in various forms, depending on their application on the human body. They can be categorized into four levels: embedded, intimate, mounted, and carried. Embedded wearables are implanted within the body, while intimate wearables are discreetly attached. Mounted wearables are visible but not covert, and carried wearables are handheld or used close to the body.

Process Lock-In: Amplifying Control and Flexibility

Integration of data from wearables enriches the application of WCM structural elements. It enhances interactivity between employees, collaborative robots, tools, product and customers. This amplification of control leads to improved productivity, quality, safety, and flexibility, creating a gamification of human metrics in line with process optimization.

Empowering People: Closing the Gap between Information and Action

Wearables empower individuals in the manufacturing setting, bridging the gap between information and action. They align actions with predefined operating procedures, enhancing the quality of applied actions and improving employee productivity.

Equipment Optimization: Leveraging Emerging Technologies

Wearables have leveraged emerging technologies such as E-SIM, miniaturization, computing power, bio-computing, cloud, neural networks, machine learning, and nanotechnology. These advancements enable wearables to be used in extreme conditions, increase operational capabilities, sensing accuracy, processing speeds, and flexibility in practical applications.

Wearables are the bridge between the analog and digital realms in the World Class Manufacturing 4.0 revolution. They empower individuals, optimize equipment, and enhance the entire manufacturing process. As we embrace this cutting-edge technology, we unlock new levels of efficiency, productivity, and quality in the world of manufacturing. The future of manufacturing has never looked brighter, thanks to the seamless integration of wearables into WCM 4.0.